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NEXON BSVI - Service Manual
1

1.2L REVOTRON ENGINE
6

CONTENTS
7

1.1 GENERAL INFORMATION
12

A. ENGINE INTRODUCTION
12

B. ELECTRONIC CONTROL UNIT
13

C. TECHNICAL SPECIFICATION
14

D. SPECIAL TOOLS
15

1.2 TROUBLESHOOTING
18

1.3 CONSTRUCTIONAL AND SERVICE DETAILS
25

A. Engine Lifting Hooks
25

B. Intake Manifold
26

C. Cylinder Head Cover
27

D. Cylinder Head-A
29

E. Cylinder Head-B
31

F. Cylinder Block
33

G. Lubrication Pump and Components
35

H. Piston, Crankshaft and Components
38

I. Engine Timing
40

J. Turbocharger, Catcon and Components
42

K. Fuel Injection Equipment
44

L. Air Filter, Snorkel and Blow-by pipe
46

M. Water Pump, Thermostat and Components
48

N. Starter Motor and Alternator
50

O. Compressor, Auto-Tensioner and Belt
51

P. Engine Suspension
52

Q. Intercooler and Hoses
55

1.4 ENGINE TESTS AND MAINTENANCE
57

A. PRELIMINARY INSPECTION
57

B. ENGINE TESTS
58

C. REGULAR MAINTENANCE
61

I. ENGINE OIL AND FILTER CHANGE
61

II. ENGINE COOLANT REPLACEMENT
63

III. AIR FILTER ELEMENT REPLACEMENT
64

IV. SPARK PLUG REPLACEMENT
65

V. AIR CONDITIONER COMPRESSOR ANDALTERNATOR BELT REPLACEMENT
67

1.5 REPAIR AND INSPECTION DETAILS
68

A. Accessory Driving Belt
68

B. Timing Chain
68

C. Cylinder Head
68

D. Valves
69

E. Cylinder Head Valve Seats
71

F. Roller Finger Follower
72

G. Hydraulic Lash Adjuster (HLA)
72

H. Camshafts (Intake & Exhaust)
73

I. Piston and Piston Rings
74

J. Connecting Rods
75

K. Crankshaft
77

L. Crank case
79

M. Fuel Tank
80

N. Canister Purge Valve
80

ENGINE70O. Canister
81

1.6 ENGINE SYSTEM
82

A. AIR INTAKE SYSTEM
82

B. BLOW BY SYSTEM
85

C. LUBRICATION SYSTEM
86

D. EXHAUST SYSTEM
90

E. COOLING SYSTEM
93

F. FUEL SYSTEM
96

1.7 ON VEHICLE SERVICE PROCEDURE
99

A. ENGINE REMOVAL AND REFITMENT
99

B. AIR FILTER ASSEMBLY
105

C. INJECTOR REMOVAL
106

D. SPARK PLUG REMOVAL
107

E. EXHAUST SYSTEM REMOVAL
108

F. FUEL SYSTEM
112

G. COOLING SYSTEM
118

H. REMOVAL OF ACCESSORIES
123

1.8 ENGINE OVERHAULING (ON OVERHAULSTAND)
125

A. ENGINE DISASSEMBLY
125

B. ENGINE ASSEMBLY
143

1.9. ENGINE MANAGEMENT SYSTEM
165

A. ABBREVIATIONS
165

B. OVERVIEW
166

C. ELECTRONIC CONTROL UNIT (ECU)
167

D. SENSORS
173

E. ACTUATORS
183

F. SWITCH
190

1.5L REVOTORQ ENGINE
199

1.1 GENERAL INFORMATION
205

A. ENGINE INTRODUCTION
205

B. TECHNICAL SPECIFICATION
206

C. SPECIAL TOOLS
207

1.2 TROUBLESHOOTING
212

1.3 CONSTRUCTIONAL AND SERVICE DETAILS
216

A. Engine Lifting Hook
216

B. Intake Manifold and Fuel Injection System
217

C. Lubrication system
220

D. Air Filter, Snorkel, Blow By Pipe
223

E. Starter Motor, Compressor and Alternator
226

F. Timing Belt, Auto Tensioner, Water pump
229

G. Exhaust manifold, Catcon, Turbocharger
232

H. Cylinder head and Components
235

I. Piston, Crankshaft and Components
238

J. Engine Suspension
240

K. Intercooler, Thermostat and Components
243

L. Crankcase and Components
246

1.4 ENGINE TESTS AND MAINTENANCE
248

A. PRELIMINARY INSPECTION
248

B. ENGINE TESTS
248

C. REGULAR MAINTENANCE
253

1.5 REPAIR AND INSPECTION DETAILS
263

A. TIMING BELT
263

B. FUEL TANK
263

C. CYLINDER HEAD
264

D. VALVES
264

E. VALVE SEATS
266

F. CRANKCASE
267

G. VALVE SEAT INSERT
268

H. HYDRAULIC LASH ADJUSTER
268

I. VALVE GUIDES
269

J. CAMSHAFT
270

K. PISTON AND PISTON RINGS
271

L. CONNECTING ROD
272

M. CRANK SHAFT
274

1.6 ENGINE SYSTEMS
276

A. AIR INTAKE SYSTEM
276

B. EXHAUST SYSTEM
279

C. COOLING SYSTEM
283

D. LUBRICATION SYSTEM
286

E. EXHAUST GAS RECIRCULATION SYSTEM (EGR)
289

F. BLOW-BY VENTILATION SYSTEM
291

G. VACUUM MANAGEMENT SYSTEM
292

H. FUEL SYSTEM
293

1.7 ENGINE ON VEHICLE SERVICE
299

A. ENGINE REMOVAL
299

B. ENGINE INSTALLATION
305

C. EXHAUST SYSTEM
306

D. COOLING SYSTEM
309

E. FUEL SYSTEM
313

F. TURBOCHARGER REMOVAL ANDREFITMENT
320

G. TIMING BELT REMOVAL AND REFITMENT
322

H. STARTER MOTOR REMOVAL ANDFITMENT – NEED INFORMATION
324

I. ALTERNATOR
325

J. COMPRESSOR
326

K. HIGH PRESSURE PUMP
328

1.8 ENGINE OVERHAULING
332

A. ENGINE DIS-ASSEMBLY
332

B. ENGINE ASSEMBLY
362

1.9 ENGINE MANAGEMENT SYSTEM
386

A. ABBREVIATIONS
386

B. OVERVIEW
387

C. ELECTRONIC CONTROL UNIT (ECU)
388

D. EMS SENSORS
393

TRANSAXLE (TA6300)
413

1. GENERAL INFORMATION
415

2. TECHNICAL SPECIFICATIONS
416

3. PRECAUTIONS
416

4. TIGHTENING TORQUES
417

5. SPECIAL TOOL
422

136. DIAGNOSIS
427

7. SECTION VIEWS
428

8. EXPLODED VIEW
430

9. REMOVAL OF TRANSAXLE FROMVEHICLE (PETROL)
437

10. REMOVAL OF TRANSAXLE FROMVEHICLE (DIESEL)
439

11. TRANSAXLE DISASSEMBLY ON BENCH
442

A. INPUT SHAFT DISASSEMBLY
448

B. LAY SHAFT DISASSEMBLY
452

C. DIFFERENTIAL DISASSEMBLY
455

D. SHIFTER SHAFTS
458

12. TRANSAXLE ASSEMBLY ON BENCH
460

13. INSTRUCTION FOR ASSEMBLY /DISASSEMBLY OF CABLE ON TRANSAXLE
464

14. REMOVAL OF GEAR SHIFTERHOUSING, GEAR SHIFTER AND SELECTOR CABLE
465

DRIVESHAFT
468

1. GENERAL INFORMATION
470

2. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE:
472

3. DRIVE SHAFT PARTS:
473

4. TIGHTENING TORQUES
474

5. ON BENCH PROCEDURE
476

A. TRIPOT JOINT DISASSEMBLY
476

B. TRIPOT JOINT ASSEMBLY
477

C. CV JOINT OUTER DISASSEMBLY
478

6. ON VEHICLE PROCEDURE
479

A. DRIVE SHAFT (LH / RH) REMOVAL(PETORL VEHICLE)
479

B. DRIVE SHAFT (LH / RH) REMOVAL (DIESELVEHICLE)
480

TRANSAXLE (TA-6300 AMT)
482

1 GENERAL INFORMATION
484

2. TECHNICAL SPECIFICATIONS
485

3. PRECAUTIONS
486

4. TIGHTENING TORQUES
487

5. SPECIAL TOOL
493

6. DIAGNOSIS
498

7. SECTION VIEWS
499

8. EXPLODED VIEW TRANSAXLE
501

9 REMOVAL OF TRANSAXLE FROMVEHICLE (FOR PETROL VERSION)
512

10 REMOVAL OF TRANSAXLE FROMVEHICLE (FOR DIESEL VERSION)
515

11. TRANSAXLE DISASSEMBLY ONBENCH
519

12 TRANSAXLE ASSEMBLY ON BENCH
538

DRIVESHAFT AMT
543

1. GENERAL INFORMATION
545

2. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE
547

3. DRIVE SHAFT PARTS
548

4. TIGHTENING TORQUES
549

5. ON BENCH PROCEDURE
551

A. TRIPOT JOINT DISASSEMBLY
551

B. TRIPOT JOINT ASSEMBLY
552

C. CV JOINT OUTER DISASSEMBLY
553

6. ON VEHICLE PROCEDURE
554

A. DRIVE SHAFT (LH / RH) REMOVAL(PETROL VEHICEL)
554

B. DRIVE SHAFT (LH / RH) REMOVAL(DIESEL VEHICEL)
555

SUSPENSION
558

1. GENERAL INFORMATION
560

2. TECHNICAL SPECIFICATIONS
564

3. TIGHTENING TORQUES
565

4. SPECIAL TOOLS
569

5. DIAGNOSIS
575

6. PRECAUTIONS
576

7. EXPLODED VIEWS FRONT SUSPENSION
577

8. EXPLODED VIEWS REAR SUSPENSION
581

9. ON VEHICLE PROCEDURE
584

9.1. REMOVAL OF FRONT STRUT ASSEMBLY
584

9.2. DISASSEMBLY OF FRONT STRUT
585

9.3. REMOVAL OF WHEEL HUB
586

9.4. REMOVAL OF SUBFRAME ASSEMBLY
590

9.5. REMOVAL OF REAR SHOCK ABSORBERAND COIL SPRINGS
595

9.6. REMOVAL OF TORSION BEAM
598

9.7. SUSPENSION PRE-LOADING CONDITION
601

STEERING
603

1. GENERAL INFORMATION
605

A. SPECIFICATIONS
605

B. SYSTEM LAYOUT
605

C. GENERAL DESCRIPTION
606

D. TIGHTENING TORQUES
607

2. MAINTENANCE, INSPECTION AND TEST
610

A. PRELIMINARY INSPECTION
610

B. REGULAR MAINTENANCE
611

C. ON VEHICLE REPAIRS
613

3. OVERHAULING
617

A. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY
617

B. PRECAUTIONS
618

C. DISMANTLING, INSPECTION AND ASSEMBLY
618

4. TROUBLESHOOTING AND DIAGNOSIS
624

5. STEERING ANGLE CALIBRATION
628

6. TUNING DATA SELECTION
631

BRAKES
633

1. PRECAUTIONS
636

2. TECHNICAL SPECIFICATIONS
637

3. TIGHTENING TORQUES
639

4. DIAGNOSIS
640

5. NESSECITY OF ABS with EBD
643

6. BRAKE HYDRAULIC LINES
644

7. VACUUM BRAKE BOOSTER
645

8. WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS)
646

9. ABS COMPONENTS
650

9.1. ABS 9 ELECTRONIC CONTROL UNIT /HYDRAULIC CONTROL UNIT (ECU / HCU):
651

9.2. HYDRAULIC CONTROL UNIT
652

9.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED)
653

9.4. ABS SYSTEM FAILURE WARNING LIGHT
654

10. MAINTENANCE, ADJUSTMENTS & TEST
655

10.1. FRONT BRAKE MAINTENANCE
655

10.2. REAR BRAKE MAINTENANCE
657

10.3 BRAKE TROUBLE SHOOTING
662

10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO
663

11. BRAKE PEDAL ASSEMBLY
665

12. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE
666

13. REPAIRS
667

13.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT
668

13.2. REMOVAL OF FRONT BRAKE DISC
673

13.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY
674

13.4. REAR BRAKE ASSEMBLY :
676

13.5. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY
677

13.6. REMOVAL OF PARKING BRAKELEVER
683

13.7. REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE
684

13.8. PARKING BRAKE CABLEADJUSTMENT
685

13.9. REMOVAL AND REFITMENT OF ABSECU / HCU
686

13.10. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR
687

13.11. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR
688

14. TROUBLE SHOOTING & DIAGNOSIS
689

15. ABS ECU CONNECTOR (K2)
691

ELECTRONIC STABILITY CONTROLINTEGRATED PROGRAM
693

1. ELECTRONIC STABILITY CONTROLINTEGRATED PROGRAM (ESCi)
695

1.1 GENERAL INFORMATION
695

1.2 WORKING OF ESCi
699

1.3 COMPONENTS
701

1.4 ON VEHICLE REPAIRS
707

1.5 TROUBLESHOOTING
708

TIRE PRESSURE MONITORING SYSTEM
709

1. GENERAL INFORMATION
711

B. SYSTEM WORKING
712

C. SYSTEM LAYOUT
712

D. COMPONENTS
713

E. ON VEHICLE PROCEDURE
714

F. TIRE REPLACEMENT
720

G. MOUNTING OF THE TIRE
721

HVAC
722

1. TECHNICAL SPECIFICATIONS
724

2. TIGHTENING TORQUES
726

3. PRECAUTIONS
731

4. HVAC SYSTEM LAYOUT AND WORKING
732

5. COMPONENTS OF HVAC
735

A. CONTROL PANEL
735

B. HVAC UNIT
737

C. COMPRESSOR
739

D. CONDENSER AND RECEIVER DRIER
740

E. ON VEHICLE INSPECTION (WITHOUT DISMANTLINGHVAC UNIT)
740

F. TRINARY PRESSURE SWITCH / PRESSURESENSOR
741

G. AIR INLET ACTUATOR
742

6. TROUBLESHOOTING
743

7. MAINTENANCE
757

A. PRELIMINARY INSPECTION
757

B. REGULAR MAINTENANCE
759

8. ON VEHICLE REPAIRS
764

i. CONTROL PANEL ASSEMBLY
764

ii. COMPRESSOR REMOVAL AND ASSEMBLY
769

iii. BLOWER REMOVAL AND ASSEMBLY
769

iv. LPM REMOVAL AND ASSEMBLY
770

v. AIR FILTER REMOVAL AND ASSEMBLY
770

vi. TXV
773

vii. PRESSURE SENSOR / SWITCH
773

viii. HVAC UNIT
774

x. CONDENSER
775

9. REFRIGERANT HOSES/PIPES
776

10. DO’s & DONT’s
777

FATC
778

1. GENERAL INFORMATION
780

2. TECHNICAL SPECIFICATIONS
782

3. TIGHTENING TORQUES
784

A. FOR PETROL VARIENT
784

B. FOR DIESEL VARIENT
787

4. COMPONENTS OF FATC UNIT
790

A. FATC UNIT
790

B. COMPRESSOR
792

C. CONDENSER AND RECEIVER DRIER
792

D. FATC CONTROL PANEL
793

5. XPRESS COOLING
796

6. HMI CLIMATE CONTRL DISPLAY
796

7. CONTROL PANEL DETAILS
798

8. FATC SENSOR & ACTUATOR
800

9. BLOWER UNIT REMOVAL AND ASSEMBLY
804

10. REAR DUCT REMOVAL AND ASSEMBLY
805

BODY
806

ON VEHICLE PROCEDURE
808

A. FRONT BUMPER REMOVAL (NEXON BSVI)
808

B. REAR BUMPER REMOVAL (NEXON BS VI)
809

C. SUNROOF
810

1. WIND DEFLECTOR
812

2. GLASS PANEL
812

3. SUNSHADE
813

4. ELECTRIC DRIVE ASSEMBLY
814

5. REAR WATER CHANNEL ASSEMBLY
815

6. CORNER COVER PIECE
815

7. CONNECTING PART
816

8. COLISSA GUIDE ASSEMBLY
816

9. RETAINING HOOK GUIDE AC
817

10. GUIDE RR AC
818

11. GUIDE FR ASSY
819

ELECTRICAL
820

1. TECHNICAL SPECIFICATION
824

2. GENERAL PRECAUTIONS
826

3. FUSE BOX / RELAY LOCATIONS
829

4. BATTERY
830

5. ALTERNATOR
832

6. STARTER MOTOR
835

7. LIGHTING SYSTEM
842

7.1 BULB SPECIFICATIONS
842

7.2 FASTENERS TORQUE VALUE TABLE
842

7.3 GENERAL SYMPTOMS AND DIAGNOSTICS
843

7.4 HEAD LAMP
846

7.5 SIDE REPEATER LAMP (LH/RH)
855

7.6 ROOF LAMP
855

7.7 HIGH MOUNTED STOP LAMP
856

7.8 TAIL LAMP (NEED PHOTOGRAPH)
857

7.9 FRONT FOG LAMP
860

7.10 REGISTRATION PLATE LAMP
861

8. HORN
862

9. WIPER & WASHER SYSTEM
864

9.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT
864

9.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY
865

9.3 WIPER AND WIPER CARE
866

10. POWER SOCKETS
868

11. FUEL GAUGE AND FUEL LEVEL METER
869

12. COMBI-SWITCH
872

13. STEERING LOCK CUM IGNITIONSWITCH (IF APPLICABLE)
878

14. FASCIA SWITCHES
880

15. HAZARD SWITCH
883

16. MIRROR SWITCH
884

17. INFOTAINMENT SYSTEM
888

17.1 SPEAKERS
891

17.2 ANTENNA (If Applicable)
892

17.3 MICROPHONE
893

17.4 SILVER BOX (XZ-HIGH VERSION)
895

17.5 TWEETERS
899

18. WINDOW WINDING MODULE
900

19 POWER WINDOW SWITCHES & INHIBIT SWITCH
902

20. STEERING WHEEL SWITCHES
906

21 DOOR HANDLE SWITCH
908

22 TAILGATE HANDLE SWITCH
909

23 IGNITION KEY (If Applicable)
910

24 INSTRUMENT CLUSTER
917

24.1 BASIC FUNCTIONAL MATRIX
919

24.2 TELL TALES INFORMATIONTELL TALES COLOR INDICATOR
920

24.3 REMINDER FEATURES
925

24.4 MAIN CONNECTOR PIN-OUTS
926

24.5 PETROL & DIESEL CALIBRATION TABLE
927

24.6 REMOVAL OF INSTRUMENT CLUSTER
928

25 IMMOBILIZER SYSTEM (IF APPLICABLE)
929

25.1 TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB
931

25.2 IMMOBILIZER SYSTEM STATUS IN EMS ECU
932

25.3 IGNITION KEY LEARNING PROCEDURE
934

26. BODY CONTROL MODULE (BCM)
937

26.1 BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX
943

26.2 BCM FUNCTIONS
950

27 CLUTCH PEDAL SENSOR
951

28 FUSE AND RELAY BOX DETAILS
954

28.1 BATTERY MOUNTED FUSE BOX (BDU)
955

28.2 ENGINE FUSE AND RELAY BOX
956

28.3 CABIN FUSE AND RELAY BOX
957

29. REVERSE PARK ASSIST SYSTEM
959

29.1 REVERSE PARK ASSIST SYSTEMDETAILS
959

29.2 ECU TO SENSOR ELECTRICAL INTERFACE
964

29.3 "REVERSE PARK ASSIST WITH CAMERA (IF EQUIPPED)
969

29.4 REAR VIEW CAMERA (if equipped)
970

29.5 TROUBLESHOOTING
972

30 PASSIVE ENTRY PASSIVE START(PEPS)
973

30.1 PEPS ECU
973

30.2 START STOP SWITCH
975

30.3 ELECTRONIC STEERING COLUMN LOCK(ESCL)
976

30.4 DOOR HANDLE SWITCHES WITHHARNESS
978

SUPPLEMENTARYRESTRAINT SYSTEM
981

1. WORKING OF RESTRAINTS
983

2. SYSTEM LAYOUT
984

3. SAFETY PRECAUTIONS
985

4. DISPOSAL OF FAULTY AIR BAG UNIT
987

5. SRS POST ACCIDENT PROCEDURE
988

6. TIGHTENING TORQUES
989

7. COMPONENTS
990

7.1. RESTRAINT WITHOUT AIRBAGS
990

7.2. RESTRAINT WITH AIRBAGS
990